Wiring Coils On A 59 Evinrude: A Step-By-Step Guide

If you're looking to wire coils on a 59 Evinrude boat engine, you've come to the right place. This process involves working with the ignition coils, which are responsible for supplying the high voltage needed to fire spark plugs. When low spark is detected on a plug, it may be time to replace a coil. Evinrude outboard engines typically have one coil per cylinder, but some designs have one coil that fires two adjacent cylinders. In this guide, we will walk you through the steps to successfully wire the coils on your 59 Evinrude boat engine.

Replacing the coils, condensers, plugs, and adjusting the carb

The ignition coils on your Evinrude outboard supply the high voltage required to fire the spark plugs. When low spark is detected on a plug, it might be time to replace a coil. Plastic-covered coils can develop cracks in the casing, or wire coverings, which can cause current leaks to the engine block. Multi-cylinder engines typically have one coil per cylinder, but some have one coil firing two adjacent cylinders.

To replace the coils, you will need to purchase the correct coil for your engine. You can refer to your boat's manual or Evinrude's website for the correct part number. Once you have the new coil, you can remove the old one by disconnecting the spark plug wire and unscrewing the coil from the engine. Then, simply screw in the new coil and reconnect the spark plug wire.

Condensers are inexpensive and are commonly replaced. They store part of the charge generated by the ignition coils when the ignition points close. A bad condenser might cause the motor to miss at higher RPMs. To replace a condenser, you will need to locate the condenser in the engine, which is usually near the ignition coils. Disconnect the old condenser and connect the new one, ensuring that the wires are properly secured.

Spark plugs are essential for engine performance and fuel efficiency. They should be replaced regularly, and you should consult your boat's manual or a marine mechanic to select the right plug. Before installing new spark plugs, examine them for any signs of damage. Check the gap of each spark plug using a gap gauge and adjust if necessary. Then, insert the new spark plug, tighten it with a wrench, and attach the spark plug wire. Repeat this process for each spark plug.

Adjusting the carb on your Evinrude boat engine can help improve engine performance. You can adjust the carb by locating the slow speed adjustment screw and turning it clockwise or counterclockwise to adjust the fuel mixture. You may need to consult your boat's manual or a marine mechanic for specific instructions on adjusting the carb.

Removing the flywheel

To remove the flywheel of a 59 Evinrude boat engine, follow these steps:

Firstly, remove the starter assembly. This will give you access to the flywheel. Next, you will need to remove the flywheel nut—this can be done with a wrench or ratchet, turning it in a clockwise direction.

Now, you can use a puller to remove the flywheel itself. This will require some force, but the flywheel should come off. Once the flywheel is off, you can continue with the rest of the process of wiring the coils. It is important to keep the workspace organised and to keep track of the order in which you are dismantling components, to ensure a smooth reassembly.

It is also important to note that the flywheel has a specific orientation, so care should be taken to ensure that it is replaced in the correct position. The word "top" should be visible on the flywheel, and this should be facing up when you are reassembling the engine.

Finally, when you are replacing the flywheel, be sure to clean your hands and any tools you are using, as oil or dirt can cause issues with the ignition.

Replacing the armature plate screws

To replace the armature plate screws on a 59 Evinrude boat engine, follow these steps:

Firstly, you will need to remove the flywheel and the armature plate. This will involve taking off the flywheel nut and using a puller to remove the flywheel itself. Once the flywheel is off, you can access and remove the armature plate.

Before removing the armature plate screws, it is important to mark the coil closest to the carburettor when the motor is in the start position. You can use a scribe mark to do this. Also, make a mark on the armature plate and slightly below it, so you know how to align it correctly when putting it back together.

Next, disconnect the shorting switch wires, the plug wire retainer on the rear of the head, and the plug wires from the spark plugs. Now you are ready to remove the armature plate screws. There should be four screws closest to the crank end holding the plate on.

When replacing the armature plate screws, it is important to note that aligning the plate with the retainer can be challenging. You may need to use small punches and a pick to align both the plate and the retainer to get one screw started. Alternatively, you can try using longer screws of the same thread count and size, grinding off the heads and as many threads as needed. As each screw is removed from the armature plate, use one of these "studs" as an alignment guide, so the plate can slip back over them, and the alignment with the retainer will be held.

Once the new armature plate screws are in place, make sure to check the tightness of the plug wires. They should be tucked away under the flywheel and not rubbing up against the cam or crank. If they are too loose, they can get damaged and create a short circuit, leading to a loss of spark.

Finally, put the flywheel back on, making sure the points cam is on the correct side (with the word "top" machine-written on the side facing up) to ensure proper timing. Hand-tighten the flywheel nut, and you are done!

Testing for spark

Before you begin, ensure you have a spark tester to hand. You will also need to remove the spark plugs.

First, check that the points are clean. Even a fingerprint can cause issues. Use acetone to clean the points before installing the flywheel.

Next, check that the wires are tucked away under the flywheel and not rubbing against the cam or crank. If they are, this will eventually damage the wires and create a short, resulting in no spark.

Now, attach the spark tester and try to start the engine using the pull rope. If you get a solid spark of at least 1/4 inch on the tester for both cylinders, you have successfully tested for spark.

If you do not get a spark, check the following:

• Ensure the flywheel nut is hand-tightened only.
• Check the points for cleanliness and adjust the gap with the feeler gauge if necessary.
• Check the coil, wire connection, and that the wires are fully inserted into the coils.
• Try spinning the flywheel faster – you may need to use the pull rope to generate a spark.

Replacing the stator

To replace the stator on a 59 Evinrude boat engine, you will need to follow these steps:

• Disconnect the battery.
• Remove the flywheel. This may require the use of a harmonic balancer puller to disengage the flywheel from the shaft. If you are having trouble, try hitting the center puller bolt with a hammer.
• Disconnect all wires going to the stator, taking note of their routing.
• Remove the screws holding the stator in place, then take out the stator.
• Install the new stator, tightening the screws to 50 inch-pounds using Loctite.
• Reconnect the wires, ensuring the woodruff key is in place.
• Reinstall the flywheel and tighten to 120 foot-pounds.
• Reconnect the battery cables.

It is important to note that the process may vary slightly depending on the specific model of your Evinrude engine. Additionally, always refer to the service manual for your engine for detailed instructions and safety precautions before attempting any repairs.

Frequently asked questions